Heat recovery apparatus and method

ABSTRACT

A grey water heat recovery apparatus has first and second passes in counter-flow orientation. The hot side is grey water. The cold side is fresh water. It extracts heat from the grey water. The fresh water is carried in tubing bundles in series immersed in grey water sumps in cylindrical plastic, mild steel, or stainless steel pipe. Both ends of the fresh water bundle assembly extend from the same upper end pipe closure, without a pressurized line wall penetration in the walls of the pipe. There is a non-electrically conductive barrier between the fresh water and grey water flow paths. The apparatus has a leak detection circuit and co-operable bypass valves. The tube bundle is wider at the top than at the bottom. The lower manifold has grey water passages between the centering ears. The entire assembly is enclosed in a unitary external housing with easily accessible connection fittings.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part of U.S. patent application Ser. No. 15/910,673 filed Mar. 2, 2018, and is also a Continuation-in-part of U.S. patent application Ser. No. 14/845,737 filed Sep. 4, 2015, which claims the benefit of the priority of U.S. Provisional Patent Application 62/046,570 filed Sep. 5, 2014; the specification and drawings of all of the foregoing being incorporated in their entirety herein by reference.

FIELD OF INVENTION

This description relates to the field of apparatus for heat recovery from grey water, particularly as in residential installations.

BACKGROUND OF THE INVENTION

It is known to recover heat from grey water that would otherwise be subject to disposal. Examples of such systems are shown in WIPO publication WO 2014/029992 of Murray, et al., and US Publication 2011/0 107,512 of Gilbert.

SUMMARY OF INVENTION

The following summary precedes the more detailed discussion to follow. The summary is not intended to, and does not, limit or define the claims.

In an aspect of the invention there is a grey water heat recovery apparatus in which heat is transferred between a grey water stream and a fresh water stream. The apparatus includes a heat exchanger that has at least a first pass and a second pass. The first pass and second pass are mounted in series. The heat exchanger has a gravity-fed grey water flow path, the grey water flow path including a first portion in the first pass, and a second portion in the second pass. The grey water flow path has a source inlet, and a drain outlet. The grey water flow path has an intermediate portion lower than the drain outlet. The heat exchanger has a pressure-fed fresh water flow path. The fresh water flow path is segregated from the grey water flow path. The fresh water flow path has a counter-flow orientation relative to the grey water flow path. The fresh water flow path of the heat exchanger is at least predominantly immersed in the grey water flow path. The fresh water flow path has a fresh water source and a fresh water outlet, both the fresh water source and the fresh water outlet is positioned at respective heights higher than the drain outlet of the grey water flow path. The heat exchanger is free of fresh water wall penetrations of the grey water flow path lower than the drain outlet of the grey water flow path.

In a feature of that aspect of the invention, the first pass and the second pass are of substantially the same size and are mounted side-by-side. In another feature, the heat exchanger has more than two passes, and the more than two passes are mounted in a side-by-side bundle. In yet another feature, the first pass includes a first shell defining an outer wall of a first portion of the grey water flow path; the second pass includes a second shell defining an outer wall of a second portion of the grey water flow path; the fresh water flow path includes a first portion and a second portion; the first portion of the fresh water flow path is nested within the first shell; and the second portion of the fresh water flow path is nested within the second shell. In a further feature, the first shell has a resting sump fluid level, and the first portion of the fresh water flow path has an entrance to and an exit from the first shell, both of the entrance and the exit is at a level at least as high as the resting sump fluid level. In another feature, the first shell has at least one plug fitting; the first portion of the fresh water flow path has an entrance to and an exit from the first shell; both of the entrance and the exit is carried through a plug fitting of the at least one plug fittings. In still another feature, the first shell is made from a cylindrical pipe; the cylindrical pipe has a first end and a second end; the cylindrical pipe has at least a first plug fitting; the first plug fitting mates with the first end of the cylindrical pipe; the first portion of the fresh water flow path has an entrance and an exit; and the entrance and the exit of the fresh water flow path are mounted through the first plug fitting.

In another feature, the first pass includes a first plastic cylindrical pipe defining an outer wall of a first portion of the grey water flow path. The second pass includes a second plastic cylindrical pipe defining an outer wall of a second portion of the grey water flow path. The fresh water flow path includes a first portion and a second portion. The first portion of the fresh water flow path includes a first coil nested within the first shell. The second portion of the fresh water flow path includes a second coil nested within the second shell. The second coil has a fresh-water connection fitting. The first and second coils are connected in series. The first and second coils are made of metal, e.g., copper or stainless steel.

In a further feature, each of the first and second coils is a copper coil. Each of the first and second cylindrical plastic pipes is predominantly upstanding. Each of the first and second plastic pipes has a bottom end closure. Each of the first and second plastic pipes has a top end closure. Each of the first and second coils has a return leg, whereby each of the first portion and the second portion of the fresh water flow path has first and second terminations, and the first and second terminations pass through the top end closure of the first and second cylindrical plastic pipes, respectively. The top end closures of the first and second cylindrical plastic pipes is higher than the drain outlet of the grey water flow path. The first and second cylindrical plastic pipes and the first and second coils extending downwardly of the drain outlet whereby the cylindrical plastic pipes define first and second sump portions, and the first and second coils are predominantly submerged in the first and second sump portions. In still another feature, there is, in combination, the heat recovery apparatus and a water heater. The fresh water flow path of the grey water heat recovery apparatus is upstream of the water heater. The water heater has supply conduits to at least a first hot water load, and the grey water flow path of the heat recovery apparatus receives grey water from at least the first hot water load.

In another feature, the apparatus includes a space filling member positioned to reduce flow path area of the grey water. In a further feature, the apparatus includes at least one return. The return is mounted within an obstructing member. The grey water is restricted to flow in an annular region outside the obstructing member. In another feature, the apparatus includes a tube bundle. The tube bundle has an outlet and an inlet. Both the outlet and the inlet are located at one end of the tube bundle whereby the tube bundle may be extracted from one end of the apparatus as a single modular unit. In an additional further feature, the tube bundle includes an inlet header, a return header, an array of feeder tubes extending between the inlet and return headers, and a return. The inlet header is mounted concentrically about the return, said return passing though said inlet header.

In another aspect of the invention, there is a grey water heat recovery apparatus in which to transfer heat between a grey water stream and a fresh water stream. The grey water heat recovery apparatus has a heat exchanger that has a first pass and a second pass, the first pass and the second pass is connected in series. The heat exchanger has a first side defining a grey water flow path, and a second side defining a fresh-water flow path. The grey water and fresh water paths are segregated from each other. The grey water flow path is a gravity-feed flow path. The fresh water flow path is a pressure-feed flow path. The heat exchanger has a grey water flow path inlet and a grey water flow path outlet. At least a portion of one of the first pass and the second pass is lower than the grey water flow outlet whereby the heat exchanger defines at least a first grey water sump. At least one of the first pass and the second pass including a first cylindrical pipe member through which to conduct the grey water stream, the first cylindrical pipe member defining a containment wall of at least a portion of the grey water flow path. The first cylindrical pipe member has a grey water inlet and a grey water outlet. The first cylindrical pipe member has a first end, and a first end member, the first end member defining a closure of the first end of the first cylindrical pipe member. A first fresh water flow element is nested within the first cylindrical pipe member. The first fresh water flow element extends axially within the first cylindrical pipe member. The first fresh water flow element has an inlet and an outlet. Both the fresh water inlet and the fresh water outlet are mounted to pass through the first end member of the first cylindrical pipe member.

In a feature of that aspect of the invention, the first fresh water flow element includes a metal coil. The metal coil has a return leg. The fresh water flow element has first and second end connections. Both of the first and second end connections of the metal coil pass through the first end of the first cylindrical pipe member. In another feature, the first and second cylindrical pipe members are mounted together side-by-side, and are mounted adjacent to a water heater. The water heater has an overall height, and the heat recovery apparatus has an overall height. The overall height of the heat recovery apparatus is in the range of 2/3 to 3/2 of the height of the water heater. In a further feature, one of: (a) the first pass and the second pass are connected to define a single grey water sump in which the grey water outlet of the first pass is connected to a lower portion grey water entry of the second pass; and (b) the first pass and the second pass are connected to define a first grey water sump in the first pass and a second grey water sump in the second pass, in which the outlet of the first sump is carried to a top portion entry into the second sump. In another feature, there is the heat recovery apparatus in combination with a water heater. The grey water heat recovery apparatus is connected as a fresh water pre-heater for the water heater.

In another aspect of the invention there is a grey water heat recovery heat exchanger. It has a first cylindrical plastic pipe for grey water with a first metal coil for fresh water nested therein. It also has a second cylindrical plastic pipe for grey water with a second metal coil for fresh water nested therein. The first cylindrical plastic pipe has an inlet for grey water. The second cylindrical plastic pipe has an outlet for grey water. The first and second cylindrical plastic pipes are connected in series to conduct grey water from the first cylindrical plastic pipe to the second cylindrical plastic pipe. The first metal coil is connected in series with the second metal coil. The second metal coil has a fresh water inlet. The first metal coil has a fresh water outlet. The fresh water coils are mounted for counter-flow operation relative to the grey water conducting first and second cylindrical plastic pipes. At least one of the first and second cylindrical plastic pipes defining at least a portion of a grey water sump in which at least a portion of the first and second metal coils is mounted.

In a feature of that aspect of the invention, at least one of the first and second cylindrical plastic pipes has a first end closure, and the corresponding one of the first and second coils has first and second end portions that pass through the first end closure. In another feature, the first and second cylindrical plastic pipes are in a predominantly upstanding orientation, and the grey water outlet of the second cylindrical plastic pipe is higher than a predominant portion of at least one of the first and second fresh water coils. In still another feature, the first and second cylindrical plastic pipes stand on a common base and are mounted together in a single mounting with both of the first and second cylindrical plastic pipes is in an upstanding orientation. The first cylindrical plastic pipe has a first end and a second end. The first end is higher than the second end. The second end of the first cylindrical plastic pipe has a blind closure. The first end of the first cylindrical plastic pipe has a closure has first and second penetrations through which pass respective first and second ends of the first fresh water coil. The first and second penetrations are higher than the grey water outlet of the second cylindrical plastic pipe. The first fresh water coil has a helical coil portion and a return leg portion. The helical coil has an outside diameter fitting within the first cylindrical plastic pipe to permit construction of the heat exchanger by axial insertion of the helical coil into the first cylindrical plastic pipe. The second cylindrical plastic pipe has a first end and a second end. The first end is higher than the second end. The second end of the second cylindrical plastic pipe has a blind closure. The first end of the second cylindrical plastic pipe has a closure has first and second penetrations through which pass respective first and second ends of the second fresh water coil. The first and second penetrations are higher than the grey water outlet of the second cylindrical plastic pipe. The second fresh water coil has a helical coil portion and a return leg portion. The helical coil has an outside diameter fitting within the second cylindrical plastic pipe to permit construction of the heat exchanger by axial insertion of the helical coil into the second cylindrical plastic pipe.

In another feature, there is the grey water heat recovery assembly in combination with a grey water drainage system, a water heater, and a hot water distribution system. The fresh water inlet of the heat exchanger is connected to a fresh water supply system downstream of a water meter. The fresh water outlet of the heat exchanger is connected to an inlet of the water heater. The water heater has an outlet connected to supply water to at least one of a hot water tap, a shower, a bath-tub, a clothes washer, and a dishwasher. The grey water drainage system is connected to a drain of at least one of a sink; a shower, a bath-tub, a clothes washer, and a dishwasher. The grey water drainage system is segregated from any sewage water system. The grey water drainage system is connected to the grey water inlet of the first cylindrical plastic pipe. The grey water drainage system includes an overflow bypass of the heat exchanger. There is a grey water inlet filter mounted to intercept objects in the grey water carried by the grey water drainage system to the heat exchanger. The outlet of the second cylindrical plastic pipe drains into a sewage drain.

In another feature of any of the foregoing aspects, the apparatus is enclosed in a unitary cylindrical housing in which both of the first and second (and any other) stages are enclosed. Externally accessible grey water and fresh water connection fittings pass through the external cylindrical housing. The fresh water connection fitting extends through a top end of the cylindrical housing. The grey water connection fittings extend through a sidewall of the cylindrical housing.

In another aspect of the invention, there is a grey water heat recovery apparatus. It has a heat exchanger having at least a first pass and a second pass, the first pass and second pass being mounted in series. The heat exchanger has a gravity-fed grey water flow path, the grey water flow path including a first portion in the first pass, and a second portion in the second pass, the first portion in the first pass being upstream of the second portion in the second pass, the grey water flow path having a source inlet, and a drain outlet. The grey water flow path has an intermediate portion lower than the drain outlet. The heat exchanger has a pressure-fed fresh water flow path, the fresh water flow path being segregated from the grey water flow path. The fresh water flow path has a first portion in the second pass, and a second portion in the first pass, the second portion of the fresh water flow path being downstream of the first portion of the fresh water flow path. The fresh water flow path of the heat exchanger is at least predominantly immersed in the grey water flow path. The fresh water flow path has a fresh water source and a fresh water outlet, both the fresh water source and the fresh water outlet being positioned at respective heights higher than the drain outlet of the grey water flow path. The heat exchanger is free of fresh water wall penetrations of the grey water flow path lower than the drain outlet of the grey water flow path. There is a non-electrically conductive barrier between the grey water flow path and the fresh water flow path.

In a feature of that aspect of the invention the apparatus includes a leak detection circuit. In another feature, the leak detection circuit includes at least a first terminal mounted in the fresh water flow path, and at least a second terminal mounted in the grey water flow path. The leak detection circuit senses at least one of (a) resistance; and (b) voltage potential between the fresh water flow path and the grey water flow path. In another feature, the leak detection circuit includes a storage member operable to provide power independently of the availability of external power.

In still another feature, the leak detection circuit is operable to adjust the flow of at least one of (a) grey water in the grey water path; and (b) fresh water in the fresh water path.

In another feature, the apparatus includes a fresh water bypass, and flow through the fresh water bypass is controlled in response to operation of the leak detection circuit. In still another feature, the apparatus includes a grey water bypass, and flow through the grey water bypass is controlled in response to the leak detection circuit.

In another feature, the first pass and the second pass are of substantially the same size and are mounted side-by-side. The first pass includes a first shell defining an outer wall of a first portion of the grey water flow path. The second pass includes a second shell defining an outer wall of a second portion of the grey water flow path. The first portion of the fresh water flow path is nested within the second shell. The second portion of the fresh water flow path is nested within the first shell. The first shell has a resting sump fluid level, and the second portion of the fresh water flow path has an entrance to and an exit from the first shell, both of the entrance and the exit being at a level at least as high as the resting sump fluid level. The first shell has at least a first closure fitting; the second portion of the fresh water flow path has an entrance to and an exit from the first shell; both of the entrance and the exit being carried through the first closure fitting.

In another feature, the apparatus includes a leak detection circuit. The leak detection circuit includes at least a first terminal mounted in the fresh water flow path, and at least a second terminal mounted in the grey water flow path lower than a resting water level therein.

The leak detection circuit is sensitive to a change in resistance between the fresh water flow path and the grey water flow path. The leak detection circuit includes a storage member operable to provide power independently of the availability of external power. The leak detection circuit is operable to adjust the flow of at least one of (a) grey water in the grey water path; and (b) fresh water in the fresh water path. The apparatus includes a fresh water bypass, and flow through the fresh water bypass is controlled in response to operation of the leak detection circuit. The apparatus includes a grey water bypass, and flow through the grey water bypass is controlled in response to the leak detection circuit. The leak detection circuit is operable to measure resistance between the first terminal and the second terminal. The leak detection circuit is operable to govern a fresh water bypass valve; and a grey water bypass valve. In a first mode of operation the fresh water bypass valve is closed and the fresh water flow path is open; and the grey water bypass valve is closed and the grey water flow path is open. In a second mode of operation the fresh water bypass valve is open and the fresh water flow path is closed, and the grey water bypass valve being open.

In another feature, the first pass includes a first plastic cylindrical pipe defining an outer wall of a first portion of the grey water flow path, the outer wall being thermally insulated. The second pass includes a second plastic cylindrical pipe defining an outer wall of a second portion of the grey water flow path the outer wall being thermally insulated. The second portion of the fresh water flow path includes a first tube bundle nested within the first shell. The first portion of the fresh water flow path includes a second tube bundle nested within the second shell. The second tube bundle has a fresh-water source connection fitting. The second tube bundle is connected in series to the first tube bundle. The first and second tube bundles being made of metal. Each of the first and second cylindrical plastic pipes is predominantly upstanding. Each of the first and second plastic pipes has a bottom end closure. Each of the first and second plastic pipes has a top end closure. Each of the first and second tubes bundles has a counter-direction leg, whereby each of the first portion and the second portion of the fresh water flow path has first and second terminations, and the first and second terminations pass through the top end closure of the first and second cylindrical plastic pipes, respectively. The top end closures of the first and second cylindrical plastic pipes being higher than the drain outlet of the grey water flow path. The first and second cylindrical plastic pipes and the first and second tube bundles extending downwardly of the drain outlet whereby the cylindrical plastic pipes define first and second sump portions, and the first and second tube bundles are predominantly submerged in the second and first sump portions. The apparatus includes a leak detection circuit. At least one of the tube bundles has a first terminal of the leak detection circuit mounted in the fresh water path therein. The grey water path includes at least a second terminal of the leak detection circuit mounted therein lower than a resting water level thereof. The leak detection circuit is operable to measure resistance between the first terminal and the second terminal. The leak detection circuit is operable to govern a fresh water bypass valve; and a grey water bypass valve. In a first mode of operation the fresh water bypass valve and the grey water bypass valve is closed. In a second mode of operation the fresh water bypass valve and the grey water bypass valve are open. In another feature, the apparatus is circumscribed by an external housing in which both of the first and second stages are enclosed, with grey water and fresh water connection fittings being externally accessible.

In still another feature, the grey water heat recovery apparatus is combined with a water heater, a leak detection circuit and a fresh water bypass. The fresh water flow path of the grey water heat recovery apparatus is upstream of the water heater. The water heater has supply conduits to at least a first hot water load. The grey water flow path of the heat recovery apparatus of claim 1 is mounted to receive grey water from at least the first hot water load; and the leak detection circuit is connected to direct fresh water through the fresh water bypass to the water heater and to shut off fresh water flow through the fresh water flow path in response to leak detection.

In another aspect of the invention, there is a grey water heat recovery apparatus. It has at least a first heat exchanger pass has an external shell and a tube bundle. The external shell is formed of a cylindrical plastic pipe. The cylindrical plastic pipe has a first end and a second end. In operation, the first end is located higher than the second end. The second end is blocked to form a sump within the cylindrical plastic pipe. The cylindrical plastic pipe has a first port and a second port. The first port is nearer the first end than is the second port. The first port defines a resting water level when gray water is contained in the sump. One of the first and second ports defines an inlet for grey water to the cylindrical plastic pipe, the other of the first and second ports defines an outlet for grey water from the cylindrical plastic pipe. The cylindrical plastic pipe defines a flow path for grey water between the inlet and the outlet thereof. The first end of the cylindrical plastic pipe provides an entrance or entry. The tube bundle is sized to fit within the entry at the first end of the plastic pipe. The tube bundle is axially slidable within the external shell on installation. The tube bundle has a first end and a second end. The tube bundle has a first manifold at the first end thereof, and a second manifold at the second end thereof. The tube bundle includes a return passing through the first manifold and extending to the second manifold. The first manifold and the second manifold fit within the cylindrical plastic pipe. As installed, the second end of the tube bundle is closer to the second end of the cylindrical plastic pipe than is the first end of the tube bundle. The tube bundle has an inlet and an outlet, the tube bundle defines a fresh water flow path between the inlet and outlet thereof. Both the inlet and the outlet of the tube bundle is located at the first end of the tube bundle. As installed in the cylindrical plastic pipe, the inlet and the outlet of the tube bundle is accessible at the first end of the cylindrical plastic pipe at a level higher than the resting water level of the cylindrical plastic pipe.

In a feature of that aspect, the cylindrical plastic pipe has at least one of (a) an inside diameter less than 8 inches; and (b) a length to diameter ratio of greater than 8:1. In another feature, the apparatus has at least a first and a second heat recovery apparatus mounted side-by-side and joined together in fluid communication in series. In an additional feature, at least the first and second heat recovery apparatus are mounted together within a single housing. In a further feature, the tube bundle includes a set of helical coils extending around the return. In a still further feature, the second end of the cylindrical plastic pipe has a valve mounted thereat, and the valve is operable to permit flushing of the sump. In still another feature, the apparatus includes a leak detector. In yet another feature, the return is at least partially insulated. In a still further feature, the tube bundle includes an array of pipes spaced about the return pipe. The array of pipes extends between, and is in fluid communication with, the first manifold and the second manifold. The array of pipes has a tighter footprint at the second manifold than at the first manifold. In another feature, the second manifold has a smaller outside wall diameter than does the first manifold.

In still another aspect, there is a grey water heat recovery apparatus. It has a cylindrical plastic pipe and a tube bundle that inserts axially within the cylindrical plastic pipe. The tube bundle has a first manifold, a second manifold, a return pipe, and a pipe array. The return pipe is in fluid communication with the second manifold and passing upwardly through the first manifold to terminate at a first pipe connection. The pipe array extends between, and is in fluid communication with both the first manifold and the second manifold. The first manifold has a second pipe connection extending upwardly therefrom, the second pipe connection is in fluid communication with the first manifold. At least one of (a) the pipe array has a smaller connection footprint with the second manifold than with the first manifold; and (b) the second manifold has a peripherally extending wall, the first manifold has a peripheral wall, and the peripheral wall of the second manifold has a shorter periphery than has the peripheral wall of the first manifold.

In a feature of that aspect, the pipe array has a smaller connection footprint with the second manifold than with the first manifold. In another feature, the second manifold has a peripherally extending wall, the first manifold has a peripheral wall, and the peripheral wall of the second manifold has a shorter periphery than has the peripheral wall of the first manifold. In another feature, the pipe array includes at least a first pipe that has a straight portion extending axially from the first manifold, and a bent portion extending from the straight portion toward the second manifold. In still another feature, the straight portion is more than twice the length of the bent portion. In another feature, the peripheral wall of the first manifold has a first diameter. In another feature, the peripheral wall of the second manifold has a second diameter. The second diameter is smaller than the first diameter. In another feature, the second manifold has a set of centering ears extending radially outwardly thereof. In a further additional feature, a grey water flow path is defined outwardly of the second manifold, inwardly of the cylindrical plastic pipe, and sectorally between an adjacent pair of the centering ears. In still another feature, the pipe array has a total cross-sectional flow area that is at least as great as the cross-sectional flow area of the return pipe.

BRIEF DESCRIPTION OF THE ILLUSTRATIONS

These and other features and aspects of the invention may be explained and understood with the aid of the accompanying illustrations, in which:

FIG. 1 is a conceptual schematic view of a building, such as a residence, having grey water sources;

FIG. 2 is a cross-sectional view of an example of a heat exchanger arrangement according to an aspect of the invention;

FIG. 3 is a cross-sectional view of an alternate embodiment of heat exchanger arrangement to that of FIG. 2;

FIG. 4 is a cross-sectional view of a cap assembly of the heat exchanger arrangement of FIG. 2;

FIG. 5 is an alternate arrangement to that of FIG. 2;

FIG. 6 is an alternate arrangement to that of FIG. 3;

FIG. 7 shows a partial view in section of a double-helical alternate arrangement to that of FIG. 2;

FIG. 8 shows a section, looking downward at the level of the upper outlet of one of the passes of a two-stage embodiment of heat exchanger such as in FIG. 2;

FIG. 9 shows a sectional view, analogous to the view of FIG. 8, looking downward, through a three-stage embodiment of heat exchanger;

FIG. 10a is a view of an alternate embodiment of a heat exchanger apparatus to that of FIG. 2;

FIG. 10b is a further view of the embodiment of FIG. 10, sectioned to show details within the heat exchange coils;

FIG. 11a shows a further alternative embodiment to that of FIG. 2;

FIG. 11b shows an enlarged fore-shortened sectional detail of the embodiment of FIG. 11 a;

FIG. 11c is a sectional view of a manifold of the embodiment of FIG. 11a ; and

FIG. 11d is a side view of a heat exchange bundle module of the embodiment of FIG. 11 a;

FIG. 12a is a side view of an alternate embodiment to that of FIG. 2;

FIG. 12b is a sectioned, vertically foreshortened view of the embodiment of FIG. 12 a;

FIG. 12c is a sectioned view looking downward and showing the pipe arrangement of the embodiment of FIG. 12 a;

FIG. 12d shows a top view of the embodiment of FIG. 12 a;

FIG. 12e shows a double-wall section of the embodiment of apparatus of FIG. 12a showing internal fluting;

FIG. 13 shows a vertically foreshortened cross-section of a further alternative embodiment to that if FIG. 12 a;

FIG. 14a shows an alternate embodiment of the apparatus of FIGS. 11a and 11 b;

FIG. 14b shows a vertically foreshortened cross-section of the apparatus of FIG. 14a comparable to the view of FIG. 11 d;

FIG. 15a is a front view of an alternate tube bundle heat exchanger assembly to that of FIG. 11 d;

FIG. 15b is a central cross-sectional view of the tube bundle of FIG. 15a taken on section ‘15 b-15 b’ of FIG. 15 a;

FIG. 15c is an enlarged detail of the upper or top end of the tube bundle of FIG. 15b showing a cross-section of the upper manifold thereof;

FIG. 15d is an enlarged detail of the lower or bottom end of the tube bundle of FIG. 15b showing a cross-section of the bottom manifold thereof; and

FIG. 15e is a cross-sectional view of the tube bundle of FIG. 15a looking upward on section ‘15 e-15 e’ of FIG. 15 a;

FIG. 15f is a cross-sectional view of the tube bundle of FIG. 15a looking downward on section ‘15 f-15 f’ of FIG. 15a ; and

FIG. 15g is a general overall perspective view of the tube bundle of FIG. 15a , foreshortened at a mid-length section.

DETAILED DESCRIPTION

The description that follows, and the embodiments described therein, are provided by way of illustration of an example, or examples, of particular embodiments incorporating one or more of the principles, aspects and features of the invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles, aspects and features. In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings may be taken as being to scale, or generally proportionate, unless indicated otherwise. In the cross-sections, the relative thicknesses of the materials may not be to scale.

The scope of the invention herein is defined by the claims. Though the claims are supported by the description, they are not limited to any particular example or embodiment. Other than as indicated in the claims, the claims are not limited to apparatus or processes having all of the features of any one apparatus or process described below, or to features common to multiple or all of the apparatus described below. It is possible that an apparatus, feature, or process described below is not an embodiment of any claimed invention.

The terminology used in this specification is thought to be consistent with the customary and ordinary meanings of those terms as they would be understood by a person of ordinary skill in the art in North America. The Applicant expressly excludes all interpretations of terminology that are inconsistent with this specification, and, in particular, expressly excludes interpretation of the claims or the language used in this specification such as may be made in the USPTO, or in any other Patent Office, other than those interpretations for which express support can be demonstrated in this specification or in objective evidence of record, demonstrating how the terms are used and understood by persons of ordinary skill in the art generally, or by way of expert evidence of a person of experience in the art.

In this discussion it may be helpful to make reference to a gravity based co-ordinate system. That is, in flow systems generally, there is a source or inlet of flow, and an outlet or discharge of flow. Fluid moves from a location of higher pressure or potential to a location of lower pressure or potential. In a fresh water supply system, the source of pressure may be a pump or an accumulator, such as a water tower, that may be used to provide or maintain a desired system head or pressure. A drain system, whether for sewage or for grey water, may be a gravity fed or gravity driven system in which the head of the flow, if any, is determined by the height of the water column of the drain. Such a system may be considered a low, or very low, head system. In either case, the system will have an upstream direction from which flow originates, and a downstream direction toward which flow occurs. In the context of the present description, gravity flow systems also include septic or other systems where the material that collects in the drainage system under the influence of gravity is then pumped out, such as, for example, to a holding tank or to a septic bed. The drainage system upstream of the septic pump is a gravity flow system within the meaning herein, even though there may be provision to pump out the downstream end or collector, or sump of the system. In such systems, there may be a separate grey water sump and grey water pump to raise the effluent to a level to reach the holding tank or to flow into the septic bed, as may be.

In this description there are cylindrical objects. In such circumstances it may be appropriate to consider a cylindrical polar co-ordinate system in which the axis of rotation of the body of rotation, or cylinder, as may be, may be considered the axial or x-direction. The perpendicular distance from the x-axis is defined as the radial direction or r-axis, and the angular displacement is the circumferential direction, in which angular distance may be measured as an angle of arc from a datum. The commonly used engineering terms “proud”, “flush” and “shy” may be used herein to denote items that, respectively, protrude beyond an adjacent element, are level with an adjacent element, or do not extend as far as an adjacent element, the terms corresponding conceptually to the conditions of “greater than”, “equal to” and “less than”.

Considering FIGS. 1 and 2, there is a building 20. Building 20 may be a residential dwelling, whether a single family home, or multiple unit residence, as may be. It may be a school or office building. However it may be, building 20 may have a water supply system 22, and a drain system 24. Water supply system 22 may include a fresh, cold water supply system, 21, and a fresh hot water supply system 23, such as may be fed from a water heater. Drain system 24 may include a septic or sewer system 26, and may include a grey water system 28. Grey water system 28 is segregated from septic or sewer system 26. Septic or sewer system 26 may be connected to toilets and utility room floor drains, for example, and may have drainage runs, or pipes, that collect at a common manifold, or drain, or riser or stack, indicated generally as 30. In either case, building 20 may have a mechanical or utility room, typically in a basement, or at foundation level.

Grey water system 28 may include one or more sink drains, whether from a washroom sink, or from a kitchen sink, or laundry tub, generically indicated as sink 32; from one or more shower drains, indicated generically as 34; from a kitchen sink or dishwasher drain, indicated generically as 36. These drains connect to a common grey water drain line or manifold, such as may be indicated as 38. Manifold 38 feeds a heat recovery apparatus 40. That is, the gravity driven grey water output or discharge flow of manifold 38 is the grey water input flow of heat recovery apparatus 40.

In the example of FIG. 2, heat recovery apparatus 40 may include an overflow bypass 42 that is connected to conduct flow arriving from manifold 38 to the main drain 50 in the event that some or all of the grey water input flow does not flow into the heat exchange components of apparatus 40, for whatever reason. Heat recovery apparatus 40 may also include an input filter, or filters, indicated as 44, to exclude solid particles or other objects whose presence or accumulation within the heat exchange elements of apparatus 40 may not be desired. The inlet filter may be placed so that the inflow into unit 40 passes partially or predominantly upward, whereby objects that might otherwise tend to accumulate on the filter element may, when the flow relents or ceases, tend to fall downward, or settle, under the influence of gravity and collect in a cleanout, such as suggested at 46, and such as may be emptied from time to time by an operator as a part of maintenance. The element, or elements, of filter 44 may also be removed, cleaned, or replaced from time to time. Ordinary flushing of cleanout 46 may be controlled by a valve 76 mounted to the cleanout sump drain outlet. The output of valve 76 leads to main drain 50. Main drain 50 carries effluent below the level of the foundation, or basement floor 55, either to the municipal sewers, or to a septic tank or bed, with or without an intervening pump-out pump as may be.

In the example of FIG. 2, heat recovery apparatus 40 includes a first stage, or pass, 52, and a second stage or pass, 54. Heat recovery apparatus 40 may be considered as a heat exchanger (or series of connected heat exchangers), in which each pass 52 or 54 (or more, as may be) is itself a heat exchanger. The stages or passes are connected in series, and in the embodiments of FIGS. 2 and 3 the inputs and outputs on the hot and cold sides, respectively, are connected in opposite directions, such that heat recovery apparatus 40 is a counter-flow heat exchanger.

In FIG. 2, following the grey water, which is presumed to be the hot side flow (that is, the incoming grey water is assumed to be warmer than the incoming fresh water supply), main grey water drain line 38 arrives at a tee 56 to which overflow bypass 42 is connected. The straight-through output line defines the infeed pipe 58 to first pass 52. It is connected to bottom union 60 at an elbow 62 that is teed into first pass 52 below filter 44. The main body of first pass 52 may be formed of a round cylindrical pipe 64 that defines the outer shell of the unit. Pipe 64 may be made of any suitable drain piping material, and may, if desired, be externally insulated. In one example pipe 64 may be PVC or ABS or metal pipe. Pipe 64 may tend to have a length that is an order of magnitude, or more, greater than its diameter. In one example pipe 64 may be an ABS pipe of nominal 4 inches in diameter (i.e., the inside wall defines a 4 inch (roughly 10 cm) diameter passageway). Other sizes may be used. In one embodiment the pipe may have a nominal 6″ (roughly 15 cm) internal diameter. Infeed pipe 58 (and all of the other grey water piping discussed herein) may likewise be any kind of pipe suitable for drain installations, and may typically be a plastic or reinforced plastic pipe, be it ABS, PVC or some other. To the extent that heat transfer through the outer wall is not desired, pipe 64 may tend not to be made of copper, or may be externally insulated, or both. The bottom end of pipe 64 is closed off. In the embodiment shown, the end closure fitting of the closed end is closed by a valve 76. Valve 76 may be opened when it is desired to flush out the clean out at the bottom of the sump. In normal operation valve 76 will be closed. At the far end of pipe 64 there is an off-take or outlet, which may be a tap or tee in the sidewall as at 66, defining the grey-water outlet or discharge of first pass 52. The uppermost end, pipe 64 is closed by another end closure or end closure fitting such as a cap or plug fitting, 70, shown in cross-section in FIG. 4, and described in greater detail below.

A transfer tube or pipe 72 extends from outlet 66 of first stage 52 to the inlet of second stage 54. Again, the inlet pipe is teed into the base of second stage 54 at the bottom, or lower portion, where there is a flushing or clean-out drain 74 controlled by a valve 76. Second stage 54 similarly has a main body that may be formed of a cylindrical pipe 78, typically of the same diameter and material as that of first stage 52, with an outlet or off-take, or discharge as at 80, and an end plug or cap or on end closure or end closure fitting as at 82. The outlet or discharge of second stage 54, being the outlet of grey water from heat recovery apparatus 40 more generally, is connected to drain into main drain 50. That is, the grey water and septic water systems are segregated upstream, but drain into a common flow at the outlet juncture, at 84. The grey water path may be considered to be the hot side, or hot path, of the heat exchanger, from which heat is extracted.

The other side of the heat exchanger, typically termed the cold side or cold path, is designated generally as 90. It is the side of the heat exchanger to which heat is transferred or rejected. The cold side may typically provide a flow for inlet water under pressure, typically 30-50 psig of a municipal fresh water supply. Inasmuch as the fresh water may typically enter from buried pipe, the cold water temperature may often be in the range of 40-50 F. The cold water pipe, being a pipe under pressure, may typically be a copper pipe, although stainless steel or any other suitable pressure line pipe may also be used.

The cold water supply, after having passed through the water meter, may have a tee at which one side is directed to the cold water outlets in the building, and another side through which fresh water flow is directed to the hot water distribution. As shown in FIG. 2, the hot water heater distribution feeder line 88 enters the second pass at an inlet 92 in cap or plug 82. The cold water supply may then have a heat exchange element 94 that is mounted to plug 82. The element may have many different forms, and may include finned heat exchange members. However, as shown, element 94 may have the form of a coil. The coil may have more than one pipe, and may include twinned pipes coiled in an axially side-by-side helix of nested helices, as in the embodiment of FIGS. 10a and 10b , for example, or in nested helices of different radii. The coils may not be circular in cross-section, but may be flattened or oval, to form a more ribbon-like section having smaller hydraulic diameter than a circular section. The coil may be a single coil of copper pipe of constant diameter and circular section, coiled on a constant radius and having regular axial pitch between the turns of the coil. At the lower end of the coil, the run in the other direction, such as may be called the “return” leg, may be a straight leg running axially or predominantly axially relative to cylindrical pipe 78, and may be a substantially straight leg 96, that also passes through cap or plug 82 to its end or termination, or outlet connection, be it a coupling, union, adapter, or other pipe fitting. The return leg 96 may run within the helix of the coiled portion, and need not be centered in the coil, but may be offset from center. The straight leg portion may be referred to as the “return” leg, although the flow may be in the opposite direction according to the manner of connecting the inlet and outlet pipe connections of element 94 (or element 102 as below). The use of the “return” terminology in this sense is intended not as an indication of internal flow direction, but rather of providing a line of shorter path length back to roughly the same entrance location as the other, coiled leg, whichever of the two may be the “inlet” or “outlet”. To avoid confusion, the term “counter-direction leg” may be used in place of “return leg”. The use and installation of such fittings are thought to be well understood by persons of skill in the art. It is assumed in this description that heat transfer between the fresh water and the grey water occurs predominantly in the coiled portion of the coil, 94, rather than in the straight leg 96.

The cold water pipe leaving second stage 54 then passes through a transfer tube or pipe 100 to first pass or stage 52. The fresh water heat exchange element 102 in first pass 52 may be different from that in second pass 54, in the general case, but may typically be the same as heat exchange element 94, and may be a helical copper coil. Again, heat exchange element 102 may have a coiled portion 101, and a straight leg portion 103. The straight leg portion may be referred to as the return leg, although the flow may be in the opposite direction according to the manner of connecting the inlet and outlet pipe connections of element 102 (or element 94 as above). Again, it is thought that heat transfer occurs predominantly between the coiled portion 101 and the grey water, much more so than as between the straight leg portion 103 and the grey water. To the extent that it may be desired to reduce heat transfer from the straight leg portion, it may be insulated. For the ranges of temperatures, and the temperature differentials, under consideration, the undesired heat transfer in the straight leg portion may be relatively small, and it may in some embodiments be used without insulation.

The outlet fresh water pipe from first pass 52 may then be carried through (i.e., connected to) piping 104 to the inlet of a domestic hot water heater 106, such that apparatus 40 functions as a pre-heater in the hot water side of the fresh water system. The hot water pipes leaving water heater 106 feed the various hot-water taps or connections in the building, such as the sinks, showers, clothes washing machine, dishwasher, and so on. The grey water system may then provide the drain, or drains, for these elements, and the heat subsequently extracted from the grey water is used to pre-heat incoming fresh water.

As may be noted, in the embodiments of FIGS. 2 and 3, the connections of the transfer lines 100 of the fresh water to be pre-heated are such that the overall direction of travel of the water in the coiled section, be it 94 or 102, is opposite to the direction of travel of the grey water in the corresponding cylindrical pipe, be it 64 or 78. That is, where the coil carries the fresh water upwards, the grey water is moving downward. Conversely, where the coil carries the fresh water upward, the grey water flows downward. In the embodiment shown, the heat exchange coils of the fresh water side of the unit may penetrate the end caps at compression fittings, indicated as 110, 112 in FIG. 4. A seal, such as an O-ring 114 may be mounted to the top end of cylindrical pipe 78 (or 64). Cap 82 (or 70, as may be) seats on O-ring 114, and is held in place by a releasable securement, such as a clamp 116. Release of clamp 116 permits insertion or extraction of coil element 94 (or 102) in the axial direction, ‘B’. In other embodiments, rather than using clamp 116, a threaded fitting may be used.

The entrance and exit of the fresh water lines to each of the heat exchange passes is above the level of the outlet drain 80 of apparatus 40. That is, even when the grey water inflow is not flowing, and the unit is passive, the water level may be expected to be at the level of the lower lip of outlet 80. As such, the dominant portion, or substantially all, or all, of the coil or coils of the coiled portion 94 (or 102, as may be) may tend to remain immersed even when the grey water is not flowing. In that sense, cylindrical pipes 64 and 78 may be considered to be, or to define, a sump or series of sumps, or collectors 122, 124, one leading to the next, in those portions lower than the outlet overflow, e.g., that of outlet 80 or 66 as may be. That is, where outlet 66 is higher than outlet 80, the resting fluid level, or resting water level, “RWL”, in sump 122 will be governed by the height of outlet 66, and the resting height of fluid in sump 124 will be governed by the height of outlet 80. Where outlet 66 is lower than outlet 80, the resting fluid level of both sumps, or sump portions, 122, 124 will be governed by the height of the height of outlet 80.

In the alternate assembly of FIG. 3, apparatus 130 is substantially the same as apparatus 40, except that the grey water inlet of first stage 132 is at, or near, the top thereof, and the transfer to second stage 134 occurs at a low level, as at transfer pipe 136 located below the coils and just above clean-out 46. The connections of the fresh water system are again such as to cause the inlet fresh water in the coiled portion to flow in the opposite direction of the grey water as the fresh water advances through the turns of the coil. In this embodiment, the height of transfer pipe 136 is well below outlet 80, so the resting grey water fluid level in both sumps is governed by the level of outlet 80. In this context, there may be considered to be two sump portions (corresponding to passes 132 and 134) of a single sump.

In the normal course of operation, fresh water is only admitted to water heater 106 (and hence to apparatus 40 or 130) when a hot water tap is opened in the building. Customarily, that water is then drained, possibly with some time delay (after the dishes are washed, the clothes washer fills and drains, or the bathtub or sink is emptied). The drained grey water, which may be warm (up to 60 C=140 F for dishwashers and clothes washers; perhaps up to 45 C=110 F for sinks, bath-tubs, and showers) as compared to ambient indoor temperature (20-25 C=68-80 F) in the building, is then the drainage inflow that displaces the grey water previously collected in the sump of the first and second stages of apparatus 40.

Although full counter flow embodiments are shown in FIGS. 2 and 3, alternate embodiments are shown in FIGS. 5 and 6. In contrast to the embodiments of FIGS. 2 and 3, in the embodiment of FIG. 5 the connections of the coils are such that in apparatus 140 the axial direction ‘A’ of flow in the helical portion of the coil as a whole (as opposed to the tangential direction flow at any point in any particular turn of the coil) is substantially the same as the direction of flow of the grey water in both first stage 142 and second stage 144. In FIG. 6, in apparatus 150 the direction of flow in first stage 152 is counter to the axial direction of flow in the fresh water coil, whereas the direction of flow in second stage 154 is in the opposite direction. The advantage of a system such as that of FIG. 6 is that the fresh-water inlets and fresh outlets are consistent, which may avoid confusion on installation. That is, in this embodiment, the inlet is always the center line, and the outlet is always the radially outward line, whether it is for the first stage of the heat exchanger or for the second stage.

In the embodiment of FIG. 7, apparatus 160 employs a double-helical coil, in which cap 162 has four penetrations and compression fittings, as at 164, 166, 168, 170 and two nested coils 172, 174. Coils 172, 174 may be on 180 degree centers, i.e., rotated half a turn relative to each other. Coils 172, 174 may be joined in parallel at their respective ends by tees 176, 178 on their respective inlets 180, 182 and outlets 184, 186. The designation “inlet” and “outlet” is arbitrary, and depends on the direction of the flows as the apparatus is installed. The provision of doubled coils may tend to increase the heat transfer surface area between the fresh water flow and the grey water flow, may also tend to increase the time (on average, double) that the fresh water fluid takes to traverse the heat exchanger stages; and, to the extent that multiple flow channels may have a greater total cross-sectional area than a single flow channel, may also tend to reduce the flow resistance in the heat exchanger. Doubled coils may be used in any of the foregoing embodiments. It is also possible to have more than two coils—there may be three or four. Although it is assumed that each coil member is circular in cross-section, they need not be. They could, for example, be oval or rectangular. It is not necessary that the coils have the same diameter or cross-sectional area as the inlet or outlet pipes—several parallel coils each of smaller diameter may in total have the same or greater cross-sectional area as the single inlet and outlet fresh water pipes. Whether one, two, or more, coils may be mounted in each heat exchanger stage, the adjacent coil turns may be held in spaced apart relationship in the axial direction of the outer cylindrical pipe (be it 64 or 78) by retainers, or spacers, or spiders, (not shown).

In the embodiments shown, the pressurized fresh water lines do not require radial penetrations of the cylinder side wall. Rather, the junction is in the end closure fitting or end plug, or cap, or closure, or closure member. A plug could also be installed in a side wall of the unit. The use of a standard fitting or cap, or plug, permits a known mating between the plug and the seat of the cylinder, which is a known mating technology, of wide availability, and of understood simplicity and reliability. It is a known technology, that is used also at the solid end or closure or plug that caps off the bottom end of the cylinder as well. In the embodiments of FIGS. 2, 3, 5 and 6, the bottom closure of each pass is governed by one or another of the clean out fittings, be it a drain fitting, or trap, or valve, 76. In operation, with the clean out fitting closed, the bottom closure may be considered as functionally equivalent to a blind end fitting or cap, or plug, i.e., without any fresh water line penetrations, as if it were a solid blank or cap through which flow does not occur. Flow only occurs through that end when the system is being flushed, e.g., to clean out debris. Where apparatus 40 is monitored or controlled by an electronic controller or timed or programmed device, the flushing or clean-out step may occur periodically, such as once a day, once a week, or once a month, and may occur at a time when it is not likely to affect operation, e.g., in the middle of the night. Given that cylinder 64 accommodates the heat exchange coil, cylinder 64 may be larger in diameter than the inlet, outlet, flushing, overflow, and other grey water flow pipes described. The coil can be pre-formed, mated with the pipe stems, and the pipe stem fittings mated to, or potted in, the end closure fitting or cap or plug. Installation (and removal or replacement, as may be) occurs by axial translation of the coil in the cylinder. In one embodiment the pipe may be ABS pipe. The pipe may be of nominal 5″ dia, with a 5″ inside diameter in which a helical coil (or coils) of 4″ or 4½″ outside diameter of coil copper pipe may be located. In another embodiment the pipe may be 6″ nominal diameter, with a 6″ inside diameter wall housing a 5″ or 5½″ diameter helical coil (or coils) may be installed. In each case, the first pass (or second pass, or third pass, etc.,), and therefore the respective reservoir, or receptacle, sump or sump portion, has a shell wall defined by the pipe. Each of those cylinders, or passes or receptacles or sumps may tend to be elongate—that is, substantially longer in the axial direction than wide in terms of diameter. In general use these members may be upstanding, being upright or predominantly upright. In a tall thin reservoir or sump, the depth and volume of the sump tend to be large as compared to the surface area of the liquid in the sump. In one example, the hydraulic diameter of the resting liquid surface may be less than one tenth of the depth of the sump below the outlet.

The penetration of the closure fitting can be potted in an epoxy or other moulded compound to form a durable seal. As the fitting penetration is located above the level of the drain, and therefore above the resting fluid level in the sump, even if the fitting should be imperfect, or if it should loosen over time, it may tend not to result in leakage, and it may tend even then to be relatively easy to obtain access to the fitting for repair or replacement.

Further, in the embodiments shown, the cylinders may tend to be substantially longer than their diameter, such that the axial flow length is much longer than the diameter of the cylindrical pipe, e.g., 10 times the length, or more. In one installation, the overall height of the cylinder is between 4 ft and 7 ft, with a diameter of about 4 inches. That is, the height may be intended to fit within the clearance provided by an 8 ft ceiling, and may be approximately the same as, or comparable to, the height of a water heater, which may typically be about 5 ft, the size depending on whether the tank is nominally 30, 40, 50, or 60 gallons. It may be that the overall height of the heat exchanger apparatus may be in the range of 2/3 to 3/2 of the height of the adjacent water heater 106. Two adjacent cylinders may be held on a common base, 118, and may be spaced from each other by yokes or frame members 120. There may be three or four such cylinders held together in a bundle. Although such a bundle of pipes might be arranged with the long axis of the pipes oriented horizontally, and the outlet at a height to maintain a resting fluid level of grey water in the cylinders as sumps, it may be more convenient, and more compact in terms of floor space occupied, for the cylinder bundle to be arranged vertically, or substantially or predominantly vertically, or upright. The pre-heater heat exchange or heat recovery apparatus, 40, may be mounted beside the hot water heater, in a furnace or other utility room, for example, and may occupy a physical footprint of comparable size, or less.

FIG. 8 shows a possible bundle arrangement in which the first and second pass cylinders 64 and 78 are placed tightly proximate to each other on a common base 118 (shown, in this instances, as being a round circular base, or plate 126) with inlet and outlet (or upper and lower) elbows 66, 67 angled on a V (when seen from above, the V being defined by the intersection of the lines of centers drawn, respectively, between the center of pipe 64 and the center of pipe 72; and between the center of pipe 78 and the center of pipe 72) such that transfer pipe 72 is nested close into the space between the two cylindrical pipes. As shown, pipe 72 may then lie within the smallest circle that circumscribes cylindrical pipes 64 and 78. In some embodiments, if a tangent line is drawn across the top edge of cylinders 64 and 78 closest to pipe 72, the proximate edge of transfer pipe 72 traverses that tangent such that the proximate edge is closer to the line of centers of pipes 64 and 78 than is the tangent line. There may be end closure plates 126 at top and bottom, and the entire assembly may be enclosed within a cylindrical shell or closure member, or skin, or housing, or cowling 128 that runs between the top and bottom members. The inlet pipe 58 and outlet pipe 80 may be mounted on the same side and parallel, as shown, for easy access and installation, or may be mounted on opposite sides, or on 90° spacing.

FIG. 9 shows an alternate embodiment to that of FIG. 8, in which the heat exchanger arrangement or assembly 190 has more than two stages in series, as indicated by first second and third stages 192, 194 and 196. The stages are arranged in a generally counter-flow arrangement to the flow of waste water. These stages are substantially similar to those shown in FIG. 8, but there are three rather than two, mounted on a common base 198. All of the cylindrical members and transfer tubes of assembly 190 fall within the projected plan profile of base 198 as a single, tight bundle. Assembly 190 illustrates that the cylinders in the bundle need not have axes all lying in the same plane. In assembly 190, while the axes are mutually parallel and defining the vertices of a triangle, such that the pipes are mounted side-by-side in a triangular configuration. Base 198 may have the form of a round plate by which the other items are circumscribed. A more-than-two-stage heat exchanger may be used where, for example, the vertical clearance is more limited. It may be that rather than having an 8 ft or 9 ft ceiling, where a 6 ft or 7 ft tall heat exchanger assembly might be used, there may be only 48, 60 or 72 inches of vertical clearance. For the same length of heat exchange coil surface, three shorter coils may be used instead of two longer coils. Similarly, four passes could also be used. As in FIG. 8, there may be top and bottom plates or end closures, and an enclosing peripheral wall, or shell, or cowling, by which the assembly is enclosed. Again the inlet pipe 58 and outlet pipe 80 may be on the same side and have parallel center line axes, or may be mounted on opposite sides, or on 90° spacing.

In the embodiments shown, as for example in FIGS. 8 and 9, a compact arrangement may facilitate mounting of the heat exchanger assembly in a basement, or utility room, and may in some instances permit the heat exchanger assembly to be mounted to a main drain stack, such as a typical 3″ diameter stack pipe, rather than necessarily being floor-mounted.

In the embodiment of FIGS. 10a and 10b , a heat exchanger arrangement 200 is substantially similar to that of FIG. 2. However, as illustrated it has a pair of coils 202, 204 in each heat exchanger pass 206, 208 respectively. In this example the coils may be ½″ copper or stainless steel pipe, that have been teed off a ¾″ supply line. The coils are wound on a common diameter and are nested axially, such that the turns of the coils alternate along the combined coil. Similarly, the return legs 210, 212 may run side-by-side back to the top of the unit, where they may again be teed back together, or fed to the adjacent pass as a twin line. For ease of modularity and facilitation of assembly and installation, a single entrance fitting and a single exit fitting (as opposed to a dual fitting) may be convenient. In one embodiment the coils may be teed together at the bottom end of the leg, and only a single, larger diameter, return leg may penetrate the top closure cover.

In FIG. 10b , the front sides of the coils have been removed to reveal an inner pipe 214 of smaller diameter. Pipe 214 is nested within outer pipe 78, such that coils 202, 204 locate in an annular cavity 216 between pipe 214 and pipe 78. For example, pipe 78 may be a 6″ i/d pipe, and pipe 214 may be a 2″ i.d. pipe, such that the annulus is 2″ wide, less the thickness of the 2″ i.d. pipe wall (the thickness of a Schedule 40 pipe being typically 3/16″, such that the outside diameter is about 2⅜″). Pipe 214 is blocked to prevent wastewater flow therethrough. It may be blocked by being mounted to, or capped by, end cap 218, or it may be blocked by an internal wall or baffle, or by a bottom end cap located at the entrance of the return legs, or leg. It may be relatively convenient for pipe 214 to be blocked by the attachment to end cover, or closure, or cap 218. Alternatively, or additionally, pipe 214 may be blocked by thermal insulation 228. That is, after installation of the return leg or legs 210, 212, the remaining space within pipe 214 may be filled with insulation, such as an expanding foam insulation. Such foam, when cured, may tend to block flow of waste water, may tend to insulate the return leg or legs, and may tend to stabilise the position of the return leg, or legs, within pipe 214.

The use of an internal filler element to occupy a greater portion of the space inside the coil may also be used in any of the embodiments described above, whether they employ single tube coils, double tube coils, or coil assemblies of more than two pipes. As in the embodiment of FIGS. 10a and 10b , the central tube is obstructed to prevent flow of the other fluid, i.e., the waste water, and the blockage may be obtained by capping the tube, by virtue of its dead-end attachment to the cap, or by the use of a flow impeding filler material such as an insulating foam. Although pipe 214 is conveniently mounted concentrically with the coil, and the return legs are mounted substantially centrally or symmetrically within pipe 214, that need not necessarily be. Pipe 214 could be eccentrically mounted, and it is not necessary that the return legs be mounted within pipe 214. The return leg or legs could run parallel to pipe 214, or could be sound about it, e.g., in an helical manner. It may, however, be convenient, and may facilitate manufacture for pipe 214 to be concentric with the coil, and, as installed, with the outer casing of the pass. The filler element, namely pipe 214, is shown as having a diameter that is about, or somewhat more than ⅓ of the inside diameter of the outer shell casing (i.e., nominal 2″ i.d. pipe (really 2⅜″ o.d.) over a nominal 6″ i.d.). The filler could be of a different size. It could be as little as ⅕ the diameter, and as much as ½ or ⅔ of the inside diameter of the outer pipe.

In this context, when the term “diameter” is used, the issue is the hydraulic diameter of the resulting flow passageway, defined by D_(h)=4A/P, where A is the area of the passageway and P is the perimeter. Reducing the hydraulic diameter, D_(h), may tend to increase the effectiveness of heat transfer. Here, in one embodiment the annulus thickness is about 2″, or a bit less (1 13/16″), and the outside diameter of the nominal ¾″ copper coils may be ⅞″, such that the coil outside diameter is approximately half of the passage width (i.e., (⅞″)/(1 13/16″)= 14/29=approximately half). The ratio could be between ⅓ and ⅔; or perhaps between ⅖ and ⅗. However ½ is convenient. While FIGS. 10a and 10b illustrate a two pass arrangement, the arrangement could have a different number of passes, be it three, or four, or some other number.

In one embodiment, the apparatus included heat exchanger modules employing stainless steel coils in a 6″ i.d. pipe, with a central 2″ i.d., Schedule 40 pipe mounted to cause waste water flow in the annulus. The apparatus was run with an inlet flow equal to the outlet flow at 10 L/min (approx. 2½ US Gal/min). In a two pass arrangement in series, with a fresh water inlet temperature of 16.2 C, and a waste water inlet at 40 C, The fresh water temperatures were 16.2 C at inlet to the first stage; 20.4 C at the mid-point between stages; and 27.1 C at the outlet leading to the water heater. The waste water temperatures were 40 C at inlet; 33.3 C at the mid-point; and 27.2 C at the outlet. The mean drop across each coil from hot side to cold side was 13 C, and, for a hot water heater outlet temperature of 55 C (130 F), the heat recovery was 28% of the heat input otherwise required to heat the water to the desired 55 C output temperature. Taking a measure of efficiency of (27.1-16.2)/(40-16.2=10.9/23.8=46% of potential heat recovery. Using the same modules in three units in series, at the same flow rate, the corresponding temperatures were fresh water inlet 17.2 C; first mid-stage temperature 20.1 C; second mid-stage temperature 24.7 C; outlet 30.1 C to hot water heater inlet. Waste water inlet 40.2 C; second mid-stage 35.7 C; first mid-stage 29.6 C and outlet 26.6 C. The mean drop across the coils from hot side to cold side was 9.5 C. For the desired 55 C water heater outlet temperature, the pre-heating was providing 34% of the heating load that would otherwise have to be provided by the heater. The corresponding measure of overall heat exchanger efficiency was (12.9/23.0)=56% of the potential recoverable heat. These measurements were taken in summer, when the inlet fresh water temperature is relatively high (17 C). In the winter, the inlet water temperature may be as low as 4 C. A larger temperature drop potential may tend to increase the potential heat recovery, and also to increase the relative efficiency. It may be noted that in the example, the coils are free of additional fin-work and free of the soldering, brazing, or other manufacturing steps associated with making more complicated fin-coil or finned-tube heat exchangers.

In FIGS. 11a-11d , there is an embodiment of heat exchanger apparatus indicated generally as 220. The external casing and piping may be taken as being substantially the same as those of the embodiments previously described. They may vary in aspect ratio. For example, the external casings of first, second, and third passes 222, 224, and 226 may be 6″ or 8″ diameter pipes. First, second, and third passes 222, 224 and 226 may be understood to be assembled and connected in a series, or counter-flow, configuration relative to the waste water flow path. Each of the passes may be taken as being of substantially the same construction, unless indicated otherwise. Apparatus 220 may differ from the apparatus previously described in having a set of longitudinal tubes 230 running between an inlet header at top end cap 240, or manifold 232, and a return or collector, or outlet manifold or header 234 at the far end of the assembly distant from top end cap 240. Inlet manifold 232 is connected to a first, or inlet, pipe 236. The outlet manifold is connected to a second, or return, pipe, or leg, 238. It may be convenient for the return leg to be centrally mounted to header 234, and to pass centrally through header 232 without being in fluid communication therewith. Inlet header 232 may have the form of an hollow cylindrical disc, or plenum that feeds tubes 230. Outlet header 234 may be similar. In one embodiment, the end cap of return header 234 may have a domed shape. It may also be convenient for the members of the set or array of tubes 230 to be mounted in an array that is concentric with return leg 238, although this need not be so. It is not necessary that return leg 238 be straight. It could be curved. It could be helical. Similarly, tubes 230 need not be straight. They could be angled or curved or helical. It is convenient that they be straight and parallel. As may be understood from FIG. 11c , tubes 230 may include an inner set of pipes 242 and an outer set of pipes 244, which may be arranged concentrically, as indicated. As also indicated, the end of return header 234 may be rounded or bulbous.

Tubes 230, manifolds 232, 234, inlet pipe 236 and outlet pipe 238 may combine to form a single tube bundle assembly 250. Assembly 250 may then be installed or removed as a single pre-assembled unit. To that end, manifold 232 has a peripheral flange 246 suited for attachment by threaded fasteners to the end of the outer housing shell pipe wall. To that end the outer housing shell pipe wall may have a corresponding thickened end or ring or flange, which may itself have corresponding tapped bores. As may be noted, outlet pipe 238 passes through both the inner and outer walls of inlet manifold 232. Seals are made on both walls with compression fittings 248. Outlet pipe 238 may be encased in insulation as at 228, or in a jacket that serves to reduce the flow path cross-sectional area in the remainder of the chamber inside the outer jacket. As with the other embodiments, whether a pipe is an “inlet” or an “outlet” is at least to some degree arbitrary. In general, the arrangements of inlets and outlets may typically be intended to cause the flow of heating and cooling fluids to be in opposite directions. As with the other embodiments, assembly 220 may include two heat exchanger passes, or three, as shown, or four, or some other larger number as may be.

In the embodiments shown, other than the forming of the coils themselves, the assembly may be made with readily available, standard fittings of copper pipe (or stainless steel pipe) and plastic components. It is intended not to require rare or specialised molded parts. That is, even if repair or replacement of parts is required many years after original installation in a relatively remote location, there is a fair possibility of obtaining standard replacement parts at a general hardware or building supply retail outlet. It may not require the shipment of a unique original equipment manufacturer part that may be of limited availability or high expense, or both.

In the embodiment of FIGS. 12a-12d , a heat recovery apparatus 260 may have a grey water supply fed into a first member, or conduit, or passage, or piping, or chamber 262 such as may have the form of a cylinder 264, which may be a cylindrical canister with an inlet at one end, as at inlet 266 at the top; and an outlet at the other end, as at 268 at the bottom. As with the other embodiments, the terms “inlet” and “outlet” are somewhat arbitrary, depending on how the fluids are run through apparatus 260. A second member, or conduit, or passageway, or chamber, or tubing or pipe, etc., defining a chamber, 270 may be mounted about chamber 262. Second member 270 may be an annular canister or tube 272 mounted about first member 262. So that a thermally conductive path may be obtained, second member 270 may be shrink fit on first member 262. Alternatively, thermally conductive members may be sandwiched between the outside surface of 262 and the inside surface of 270. It may be convenient that the two members be concentric. Member 270 has a fresh water outlet as at 274 and an inlet as at 276. Inlet 276 may be bifurcated (or may have several inlet legs or return legs, however they may be called depending on the direction of flow), as at 278, that meet in, or extend away from, a common manifold, as at 280. Either or both of outlet 274 and inlet 276 may have multiple branches connected by a common manifold. A third member 282 such as may be a conduit, pipe, tube, chamber, etc., may be indicated as an annular outer cylinder or canister 284. As before, it may be mounted concentrically about members 262 and 270, and in one embodiment it may be shrink fit onto the outside of member 270. Third member 282 may have an inlet, or inlets, 286 that is, or are, fed from outlet 268 of first member 262. The lowermost point of the connecting piping may also have a sump drain, such as may be controlled by an outlet valve 290, which may be a solenoid controlled valve. Third member 282 has an outlet 288, which may be taken as being the same as outlet 80, above. Optionally, either or both of members 270 and 282 may have vanes or a helical baffle or baffles, indicated respectively at 292 in member 270 and at 294 in member 282, such as may tend to cause the flow to move in a swirling or helical path and such as may tend to enhance heat transfer to the respective conductive walls. Alternatively, either or both of the grey water or fresh water inlets to members 270 and 282, respectively, may be arranged tangentially in such a manner as to impart a circumferential component of velocity to the flow inside the various canisters. Alternatively, flow directing members, or baffles, may be mounted in a maze, or zig-zag, or serpentine arrangement such as may tend to enhance heat transfer at the conduction wall.

In this embodiment, either of the outside wall of member 270 or the inside wall surface of member 282 may have splines or flutes 296. The same may also apply at the interface between item 262 and item 270. The double-walled interface between member 262 and member 270; and between member 270 and member 282 may tend to require a double failure for the flow of fresh water and waste water to mix. Inasmuch as the bottom of the unit is open, in the event of even a single failure, dripping from the bottom of the unit may tend to indicate that a failure has occurred. The unit may be provided with an electronic moisture sensor to trigger an alarm condition in the event of moisture detection in the bottom of the unit. Where there is grooving at the interface between the units, as due to splines or flutes, such grooving may tend to permit any leaving material to drain.

Assembly 260 may be connected, e.g., in series, with other such assemblies as in the manner of the other modules described above. However many such modules there may be, they may be enclosed within a housing, such as cowling 128. Such an enclosure may have a leak drain, internal moisture sensor, and alarm, as discussed.

As noted in respect of the other embodiments described above, it may be arbitrary which is an “inlet” and which is an “outlet”. Likewise, the sense of fresh water inlet and outlet could be reversed such as to cause the inlet flow to be generally in the opposite direction to the flow in the outer grey water canister.

In the embodiment of FIG. 13, rather than having a three-layered concentric unit of members 262, 270 and 282, a heat exchanger assembly 300 may have a single fresh water member or canister 302 nested concentrically within an outer waste water canister 304. As before, there is a double-walled interface between the fresh-water and waste water sides of the unit.

The drawings of the Figures may not be to scale. As noted above, in FIG. 12a , the outside diameter of member 262 may be 2 inches, corresponding to the inside diameter of member 270. The outside diameter of member 270 may be 3 inches or four inches, which corresponds to the inside diameter of member 282. The outside diameter of member 282 may be 4 inches (where i.d. is 3 inches) or 5 or 6 inches (where i.d. is 4 inches). In terms of general proportions, the overall height of the canisters, indicated as h₂₆₀, in respect of assembly 260 of FIGS. 12a-12e , and h₃₀₀ in respect of assembly 300 of FIG. 13, may be of the order of 1 m or 40 inches. It could of course be as short as 30″ to 36″, and as tall as 60″, 72″, or 78″. In one particular embodiment, the inner canister may be about 2″ (5 cm) in diameter, the fresh-water annulus may have a radial thickness of about ½″ (13 mm) (giving an outside diameter of about 3″ (7½ cm)). The aspect ratio height to diameter of the unit, assembly 260, overall, is then about 10:1. The aspect ratio may be in the range of about 5:1 to about 20:1. For assembly 300, the overall aspect ratio ranges may be roughly the same. The various tubes and canisters may be made of metal, such as copper or stainless steel, and the parts may be assembled as by heat shrinkage onto each other. The connection at the grey water inlet may include an adapter between a non-metallic pipe, such as ABS, and a metallic pipe of the heat exchanger assembly, be that pipe copper or stainless steel, for example. The connections to fresh water supply and to the water heater, and the connections to the grey water drains and stack may be understood as being the same, or substantially the same, as described above. The fresh water supply conduit may typically be taken as ¾ inch copper upstream and downstream of the unit, be it 260 or 300.

A further embodiment of a grey water heat recovery apparatus 320 is shown in FIGS. 14a and 14b . It may be taken as being the same as the apparatus of corresponding FIGS. 11a-11d , with like parts being labelled with the same annotation numerals. FIG. 14a shows a single pass 322 of apparatus 320, and may be understood as being generically comparable to any of the passes shown in FIG. 11a with corresponding pipe connections as may be. Apparatus 320 is shown with an external layer of thermal insulation, or a thermal insulation jacket, as at 324. In the embodiment shown, jacket 324 extends from the top of the outer wall to the bottom of the outer wall close to valve 76. Further thermal insulation mounted to extend around the inlet and outlet waste water conduits, as at 326 and 328. The outside wall structure of the grey water sump, that is, of shell 78, may be made of stainless steel or ABS plastic.

Apparatus 320 includes a heat exchanger fresh water pass or core or bundle or tube bundle assembly 330 that has the same structure as tube bundle assembly 250, having a set of longitudinal tubes 230 running between an inlet header at top end cap 240, or manifold 232, and a return or collector, or outlet manifold or header 234 at the far end of the assembly distant from top end cap 240. Inlet manifold 232 is connected to a first, or inlet, pipe 236. The outlet manifold is connected to a second, or return, pipe, or leg, 238. It may be convenient for the return leg to be centrally mounted to header 234, and to pass centrally through header 232 without being in fluid communication therewith. Inlet header 232 may have the form of an hollow cylindrical disc, or plenum that feeds tubes 230. Outlet header 234 may be similar. In one embodiment, the end cap of return header 234 may have a domed shape, all as described above in the context of FIGS. 11a-11d . As above, it may also be convenient for the members of the set or array of tubes 230 to be mounted in an array that is concentric with return leg 238, although this need not be so. It is not necessary that return leg 238 be straight. It could be curved. It could be helical. Similarly, tubes 230 need not be straight. They could be angled or curved or helical. It is convenient that they be straight and parallel. As with the other embodiments, whether a pipe is an “inlet” or an “outlet” is at least to some degree arbitrary. In general, the arrangements of inlets and outlets may typically be intended to cause the flow of heating and cooling fluids to be in opposite directions. As with the other embodiments, assembly 320 may include two heat exchanger passes, or three, as shown, or four, or some other larger number as may be.

Assembly 330 may then be installed or removed as a single pre-assembled unit. Tube bundle assembly 330 differs from assembly 250, however, in that it is internally coated, or externally coated, or both internally and externally coated, in a non-electrically conductive coating, as indicated notionally at 332. It is applied to all surfaces, such that a continuous electrical barrier is formed. Coating 332 may be of small or very small thickness relative to the size of the parts of apparatus 320 generally. In one embodiment the non-electrically conductive coating may be paint, or enamel, or epoxy. A non-conductive or dielectric coating may be a hygienic polyurethane or silicone compound. The non-conductive coating may be applied, either internally or externally, e.g., as by dipping in a bath, followed by subsequent curing. However applied, the non-electrically conductive coating is, and functions as, a non-conductive coating between the fresh water and waste water paths of the heat exchangers.

Assembly 330 is also provided with one sensor or one terminal (which may be an array of sensors or terminal ends distributed to various locations along the fresh water flow path) indicated as 334 of an electrical conductivity sensor assembly or circuit, 340. In some embodiments, the first sensor may be located in one of the end manifolds of the tube bundle, and, in particular, it may be located in the upper manifold. A second terminal, or an array of second termini, 336 is similarly located in the waste water pass. Terminal 336 may be located below the standing water level of the sump, i.e., below the resting water level RWL of the particular sump. In some embodiments it may be located near the bottom of the sump, and the wiring of the sensor may be run back to the top of the sump, and pass through the shell wall where it may be twinned with the lead of the other sensor terminal and joined in a common plug or connector. Electrical conductivity terminals 336 may be mounted in each sump of each pass of the waste water heat recovery apparatus to permit detection of a leak in whichever pass it should occur. Terminals 334 may be mounted in each fresh-water pass, and may be formed into a combined terminal connector for each pass, as at 354. In another embodiment, a single terminal 334 in a continuous fresh water path may also be used, since a rise in conductivity in any of the sumps will be sensed in the fresh water line.

Electrical conductivity sensor assembly or circuit 340 may be a capacitance based or a resistance based conductivity sensor assembly. That is and said leak detection circuit senses at least one of (a) resistance; and (b) voltage potential between said fresh water flow path and said grey water flow path. It may include a power supply 338. Power supply 338 may be a DC supply of low or very low voltage. This power supply has a power storage capability, e.g., such as a battery, such that it will continue to operate if electrical power has failed in the building more generally, as in the case of a power outage. That is, leak detection circuit 340 includes a storage member, e.g., a battery, which operates to provide power independently of the availability of external power such as from municipal power or from building power generally. Thus, even if fresh water pressure is lost due to an electrical pump failure or other upstream flow interruption or shut off, for example, circuit 340 will remain in operation. Circuit 340 may also include a signal output annunciator or alarm or display, indicated at 342, which may include a normal signal (e.g., a green light) to indicate that the system is in operation but not in a fault condition; and an alarm signal whether noise-making or visual, or both, or that sends an electronic message to a message receiving device, such as a phone or e-mail address, or any combination of them (e.g., a red light, or fault, or alarm condition). Display 342 may be part of a controlling microprocessor, or controller 344. In normal operation, circuit 340 detects an open circuit between terminal 334 and terminal 336. However, in the event that a leak should develop between the fresh water system and the waste water system, circuit 340 detects a conductivity path, and provides an alarm signal corresponding to that red light, fault, or alarm condition.

Electrical conductivity sensor circuit 340 may also control the operation of valves by which to adjust operation of assembly 330 from a first condition or position or configuration (e.g., normal operation) to a second condition or position or configuration (e.g., a fail-safe condition). That is, assembly 330 may be provided with a first solenoid controlled valve (S1) indicated as 346 and a second solenoid controlled valve (S2), indicated as 348. It is arbitrary which valve is designated as the first or second valve.

Considering the elements as also shown in FIG. 1, the detection of electrical conductivity between terminals 334 and 336 is interpreted as being an indication of a leak between the fresh water and waste water sides of the heat exchanger. In normal operation, this should be benign, since the fresh water system is pressurized typically at 30-50 psi., and the waste water system is essentially at ambient, i.e., less than 5 psi., such that any leak will flow away from the fresh system to the waste system, and not into the domestic supply. However, in the event that source pressure is shut off in the fresh water system, and a leak is detected, the first of the solenoid controlled valves, 346 opens the sump drainage valves and dumps the waste water sumps (however many there may be) directly to drain 30. At the same time, the second of the solenoid controlled valves 348 opens the fresh water bypass 350, such that fresh water supply is directed around the waste water heat recovery apparatus and directly to water heater 106 (or to such other fresh water supply line as may be, whether hot or cold). Where source pressure is applied through the bypass valve 348, a check valve is positioned in the fresh water output line 104 is placed to prevent back flow into the waste water heat recovery heat exchanger passes. Apparatus 320 may also be provided with a fresh water shut-off valve 352 which may be co-operably mounted with fresh water bypass valve 348, and that may prevent additional fresh water from flowing into the waste water heat recovery apparatus. In some embodiments, the respective sump valves 76 may be the solenoid controlled valve, or valves, 346.

The leak detection features of apparatus 320 may be applied to the other embodiments shown or described herein, whether having coils or tube bundles. The leak detection circuit operates to govern whether flow is directed (in one mode) through the fresh water flow path or (in another mode) through the fresh water bypass e.g., directly to the water heater, as when a leak is detected. Similarly, the leak detection circuit governs whether grey water is directed in a first mode to the grey water flow path, or, in a second mode, is directed to the drain.

In the embodiments shown, other than the forming of the coils or tube manifolds themselves, the assembly may be made with readily available, standard fittings of copper pipe, or mild steel pipe, or stainless steel pipe, and plastic components. Other than the tube manifolds, it is intended not to require rare or specialised molded parts. That is, even if repair or replacement of parts is required many years after original installation in a relatively remote location, there is a fair possibility of obtaining standard replacement parts at a general hardware or building supply retail outlet. It may not require shipment of a unique original equipment manufacturer part that may be of limited availability or high expense, or both.

FIGS. 15a-15g illustrate an alternate form of tube bundle assembly 360 to that of item 230 of FIG. 11a or 250 of FIG. 11d . It has an upper manifold 356, a lower manifold 358, a first member identified as central pipe or central tube 362, and a second member, or second members in the form of a surrounding array of pipes or tubes 364 that extend between the upper and lower manifolds 356, 358. As before, tube 362 and array of tubes 364 carry fresh water under pressure. Also as before, whichever direction the fresh water may flow in central tube 362, it flows in the opposite direction in tubes 364. In that context, whatever direction the water may flow, tube or pipe 362 may be referred to as the “return”. This choice is arbitrary, and, as above, depends on the fresh water pipe fitting connections. The “return” passes through the upper manifold without being in fluid communication with the upper manifold. The return then extends upwardly beyond the upper manifold to define one or the other of inlet or outlet pipes 92 and 98. As illustrated, it is arbitrarily designated as fresh water outlet pipe 98. Accordingly, as above, both the inlet and outlet fresh water pipes 92, 98 have their ends located for connection at one end of tube bundle assembly 360, namely at the top end, above the resting water level in the sump.

As before, upper manifold 356 is bounded by upper and lower closure plates, or bulkheads, identified as upper and lower annular plates 366, 368; and by inner and outer peripheral walls, namely inner wall 370 and outer cylindrical wall of larger radius 372. Although these peripheral walls need not be circular cylinders, it is convenient that they are. The outer radius of lower annular plate 368 and the outer radius of outer cylindrical wall 372 are such that their diameters seat closely within, and may seat in a gentle interference fit within, the inside surface of the outer cylindrical wall defined by a cylindrical pipe 64 or 78, such as previously seen in FIGS. 2, 3, 5, 6, 10 a and 11 b, for example. As before, that cylindrical pipe may be plastic. Alternatively, it may be metal (e.g., copper, mild steel, or stainless steel), and may be wrapped in an external layer of thermal insulation. The outer diameter of upper plate 366 may extend, and in the illustrated embodiment does extend, radially outwardly proud of cylindrical wall 372, such as to define a peripheral flange 374. The annular surface of flange 374 may seat on the end of pipe 64 or 78, and may be secured there with fastening hardware, such as bolts passing through the holes seen at 376. Alternatively, as illustrated in FIGS. 15c and 15d , pipe 64 or 78, as may be, may include a straight cylindrical pipe portion, and, additionally, at one end, namely the upper end as illustrated, the assembly may include a pipe coupling 68 mounted to the outside of the pipe. In the embodiment illustrated, the depth of inlet or upper manifold 356 is less than the axial length of pipe coupling 68, such that when part of pipe coupling 68, i.e., its lower margin, is mounted to the pipe, the remainder of coupling 68 leave an internal cavity or accommodation of the diameter of the inside of the coupling, axially above the shoulder defined by the end of the cut pipe. As such, upper manifold 356 seats within this larger diameter cavity, since the outside diameter of the outer peripheral wall 372 is the same, or substantially the same, as the outer diameter of the cut pipe. A circular seal, or O-ring may also be provided for location between flange 374 and the end of the respective pipe coupling 68, as may be. The inner diameter of annular cylindrical wall 370 provides a clearance passage for return pipe 362. An annular bushing or seal 378 may be located in this space to center pipe 362 relative to wall 370, and therefore relative to upper manifold 358 generally. In the examples given, members 64, 78 and so on may be 4″ nominal diameter ABS pipe, and coupling 68 may be a corresponding 4″ standard pipe coupling. Cylindrical wall 372 and flange 374 may be sized accordingly. Other standard sizes of diameter pipe and standard pipe couplings could be used, e.g., 5″ or 6″, whether of plastic, steel, or stainless steel, as may be. As noted, the use of standard, commercially available pipe sizes is intended to simplify construction and repair or maintenance such as may be required. The use of coupling 68 may facilitate assembly and increase the room available for the inlet and outlet ports for the fresh water. For example, where outlet pipe 98 is on the axial centerline of the unit, the use of pipe coupling 68 permits inlet pipe 92 (of the same standard dimension as outlet pipe 98) to be mounted in top wall 366 as well, within the room provided by the diameter of outer peripheral wall 372.

As before, plates 366, 368 and cylindrical walls 370, 372 co-operate to define an enclosed volume or chamber 380 that has a port connected to fresh water inlet pipe 92, and outlets connected to each of the pipes 364 of the array of tube bundle assembly 360. It may be noted that fresh water inlet pipe 92 may be the outlet pipe, depending on the manner of connection. Pipes 92 and 98 (or 362) may be, and in the embodiment illustrated are, of larger diameter than the pipes of the heat exchanger array, namely pipes 364. Pipes 92 and 98 may be, and in the embodiment illustrated are, of the same diameter, and may be ¾″ (20 mm) pipes such as are commonly used in residential water supply systems in North America. Pipes 364 may be, and in the embodiments illustrated are, smaller in diameter, and may be, for example, ¼″, ⅜″ or ½″ pipes. The total cross-sectional area of pipes 364, summed together, may be, and in the embodiment illustrated is, as great as, or greater than, the cross-section of either of pipes 362 (or 98) and 92. The array of pipes 364 may meet the ports, or holes, or fittings of lower plate 368 on a pitch circle, D₃₆₄ which is twice the pitch circle radius, R₃₆₄ indicated in FIG. 15e . The pipes of that array may be equally spaced around the pitch circle. This apparatus also has an air bleed valve at 382.

Looking at the lower end of heat exchanger tube bundle assembly 360, lower manifold 358 has an upper plate 384, a lower plate 386 and an outer peripheral wall 388 that co-operate to form an enclosed space or chamber 390 that is contained within the end cap or dome defined by lower plate 386 as before. Upper plate 384 has ports, or opening, or holes, or accommodations, or seats, or fittings formed in it to receive the lower ends of return pipe 362 and of pipes 364. As may be seen in FIG. 15f , the opening 392 for pipe 362 may be, and in the embodiment illustrated is, located centrally in plate 384. Respective openings 394 for pipes 364 may be, and in the embodiment illustrated are, equally spaced around a pitch circle having a diameter D₃₉₄, which is twice the radius R₃₉₄ indicated in FIG. 15 f.

Plate 384 has an outer peripheral diameter indicated as D₃₈₄. It also has protrusions, or tabs, or tangs, or abutments, or spacers, or toes, or fingers, or ears, indicated as 396, however they may be called, that extend or protrude radially outwardly proud of, i.e., radially beyond, the outer peripheral diameter D₃₈₄. Fingers 396 define a spider that centers the lower end of tube bundle assembly 360 within pipe 64 or 78, as may be. In some embodiments fingers 396 may be dimensioned to fit closely within the inside wall of pipe 64 or 78, and may touch that wall. Three such fingers are sufficient for centering, although a greater number may be used. In the embodiment shown there are four ears 396. They are spaced equally around plate 384. In any event, spaces, or accommodations, or gaps, or reliefs, or rebates, or openings, or passageways 400 are formed about the periphery of plate 384, in the open sectors remaining in the generally annular space between the outside periphery of plate 384 at diameter D₃₈₄ and the inside wall of pipe 64 or 78, in the radial direction, and by spaced pairs of ears 396 in the circumferential direction. This gap, or set of gaps, or openings 400 collectively from a passageway, or passageways, or a gallery of passageways through which the grey water may pass. The radial width, or radial extent, of such a gap 400 may be at least nominally taken as being the length of ears 396, indicated as h₃₉₆. The overall dimension of the lower manifold assembly across ears 396 is shown as D₃₉₆. It is less than or equal to the overall diameter of the outer peripheral wall 372 of upper manifold 356, and, where the external grey water containment shell employs pipe coupling 68, it is less than or equal to the inside diameter of coupling 68, or, equivalently in practical terms, less than or equal to the outside diameter of the cut pipe of pipe 64 or 78.

Lower manifold 358 may tend to obstruct the pathway for the flow of grey water. To provide a greater overall cross-sectional area for the grey water to pass with less obstruction, the spacing of the lower ends of pipes 364 at plate 384 is tighter, or closer together, than the spacing at the top of pipes 364 at plate 368. This permits diameter D₃₈₄ to be smaller, and the size of gaps 400 to be relatively larger, than otherwise. Toward this end, pipes 364 in the outer array could be set on a straight taper continuously from end to end. Alternatively, as shown, upper portions 402 of tubes 364 are parallel to the longitudinal direction, and the lower portions 404 are angled inward, i.e., deviate radially inward. That is, pipes 364 are bent pipes, not straight pipes, there being a bend, or elbow, or kink between the upper and lower portions as at 406, lower portion 404 being much shorter than upper portion 402. In the embodiment illustrated, lower portion 404 is roughly ⅛ of the overall length of pipes 364, such that the majority, being the large majority, of each of pipes 364 extends at the larger radius R₃₆₄ such as may tend to permit the flow of grey water more easily between and around pipes 364. This can be expressed in several ways. The pitch circle of the lower grouping of pipe ends or fittings on radius R₃₉₄ is smaller than the pitch circle at the upper grouping of pipe fittings or ends on radius R₃₆₄. Alternatively, if a periphery is drawn around the pipe ends, i.e., all of the pipes are circumscribed by the shortest external boundary line that can be drawn, the overall footprint area of the bottom ends of the pipe array is smaller than the corresponding footprint at the top ends, although the total cross-sectional area of pipes 364 is the same at both ends. The gap between pipes 364 and the outside wall of return pipe 362 is smaller at the bottom than at the top. As may be noted, the total cross-sectional area of the grey water path is greater than the total cross-sectional area of pipes 364. In the embodiment shown, the sum of the grey water area in gaps 400 is more than double the internal area of the fresh water pipes 364.

In summary, assembly 360 is for use in a grey water heat recovery apparatus and is installed in a shell, such as a plastic cylindrical tube or pipe to define a first heat exchanger pass for use in the various embodiments described above. The external shell may be pipe 64 or 78. The pass has a tube bundle assembly, namely assembly 360. The external shell can be formed of a cylindrical plastic pipe 64 or 78. The external shell can also, alternatively, be formed of a mild steel or stainless steel pipe with a layer of thermal insulation, or a plastic pipe with an additional layer of thermal insulation. The cylindrical plastic pipe has a first end and a second end. In operation, the first end is located higher than the second end—the grey water flow path is a gravity flow conduit. The second end, i.e., the bottom end is blocked to form a sump within the cylindrical plastic pipe. The cylindrical plastic pipe has a first port and a second port; the first port is nearer the first end than is the second port. The first port defines a resting water level when gray water is contained in the sump. Depending on which way the pipe is connected, one of the first and second ports defines an inlet for grey water to the cylindrical plastic pipe, the other of the first and second ports defines the outlet for grey water from the cylindrical plastic pipe. Accordingly, the cylindrical plastic pipe defines a flow path for grey water between the inlet and the outlet thereof. The first end of the cylindrical plastic pipe providing an entry, or entryway, into which to admit the lower end, and substantially the entire body of assembly 360, up to flange 374, which acts as a stop to locate assembly 360 longitudinally in its axially installed position relative to pipe 64 or 78 (or such other as may be). The tube bundle is sized to fit within the entry at the first end of the plastic pipe. The outside peripheral cylindrical wall of the upper manifold is sized to nest with little or no slack or tolerance within the open end of pipe 64 or 78. During installation the tube bundle is axially slidable within the external shell to reach the position dictated by the abutment of flange 374 with the cut end of pipe 64 or 78. The tube bundle has a first end and a second end. The tube bundle has a first manifold 356 at the first end (i.e., the upper or top end) thereof, and a second manifold 358 at the second end (i.e., the lower or bottom end) thereof. The tube bundle has a return, namely return pipe 362, passing through first manifold 356, and extending to second manifold 358. First manifold 356 and second manifold 358 fit within the cylindrical plastic pipe. As installed, the second end (i.e., the bottom end) of the tube bundle is closer to the second end (i.e., the bottom end) of the cylindrical plastic pipe than is the first end (i.e., the top end) of the tube bundle. The tube bundle has an inlet 92, and an outlet 98. The tube bundle defines a fresh water flow path between inlet 92 and outlet 98. Both inlet 92 and outlet 98 are located at the first end of the tube bundle. As installed in the cylindrical plastic pipe, the inlet and the outlet of the tube bundle are accessible at the first end of the cylindrical plastic pipe at a level higher than the resting water level of the cylindrical plastic pipe.

In that assembly, pipe 64 or 78 has at least one of (a) an inside diameter less than 8 inches (in the embodiment illustrated it may be about 4″ i.d.); and (b) a length to diameter ratio of greater than 8:1. As illustrated in the previous embodiments, a counter-flow heat exchanger assembly may include two, three, or more such passes mounted side-by-side and joined together in fluid communication in series. As shown in FIG. 8 and FIG. 9, first and second, or first second and third such heat recovery apparatus can be mounted together within a single housing, e.g., housing 128. It may include straight legs, or it may include a set of helical coils extending around, i.e., wound around, the return pipe, 362. The second end of the cylindrical plastic pipe has a valve 76 mounted thereat. Valve 76 is operable to permit flushing of the sump, as, for example, when there is a sediment build-up in the bottom, as in a trap, or at any time that a filter may indicate that periodic cleaning may be advisable. As described, the grey water and fresh water sides of the apparatus are segregated. The fresh water side is typically at much higher pressure than the grey water side, such that any leak may flow out of the fresh water side into the grey water side. In any case, the assembly may be given a non-electrically conductive coating, and leak detection sensors may be mounted, and monitored, such that the apparatus includes a leak detector. The return pipe is at least partially insulated, or isolated, and part of that insulation or isolation may be mounted in the annular gap between inner annular wall 370 and pipe 362. The tube bundle includes an array of pipes 364 spaced about return pipe 362. The array of pipes extends between, and is in fluid communication with, first manifold 356 and second manifold 358. The array of pipes has a tighter footprint at the second manifold than at the first manifold. Alternatively expressed, the second manifold has a smaller outside wall diameter of wall 388 than does the first manifold at outer peripheral wall 372.

In that assembly, the grey water heat recovery apparatus has a cylindrical plastic pipe and a tube bundle that inserts axially within the cylindrical plastic pipe. The tube bundle has a first manifold, a second manifold, a return pipe, and a pipe array. The return pipe is in fluid communication with the second manifold and passes upwardly through the first manifold to terminate at a first pipe connection. The pipe array extends between, and is in fluid communication with, both the first manifold and the second manifold; the first manifold has a second pipe connection extending upwardly therefrom, the second pipe connection is in fluid communication with the first manifold. The pipe array has a smaller connection footprint with the second manifold than with the first manifold. The second manifold has a peripherally extending wall. The first manifold also has a peripheral wall. The peripheral wall of the second manifold has a shorter periphery than has the peripheral wall of the first manifold. Expressed differently, the pipe array has a smaller connection footprint with the second manifold than with the first manifold. The pipe array includes at least a first pipe that has a straight portion extending axially from the first manifold, and a bent portion extending from the straight portion toward the second manifold. In that array, the straight portion of the pipe is more than twice the length of the bent portion (in the embodiment shown it is more than 7 times the length of the bent portion, the straight portion being more than ⅞ of the overall length). Alternatively expressed, the peripheral wall of the first manifold has a first diameter. The peripheral wall of the second manifold has a second diameter. The second diameter is smaller than the first diameter. In another feature, the second manifold has a set of centering ears extending radially outwardly thereof. The grey water flow path includes portions or passages defined outwardly of the second manifold, inwardly of the cylindrical plastic pipe, and sectorally between an adjacent pair of the centering ears. The pipe array has a total cross-sectional flow area that is at least as great as the cross-sectional flow area of the return pipe.

What has been described above has been intended illustrative and non-limiting and it will be understood by persons skilled in the art that changes and modifications may be made without departing from the scope of the claims appended hereto, particularly in terms of mixing-and-matching the features of the various embodiments as may be suitable. Various embodiments of the invention have been described in detail. Since changes in and or additions to the above-described best mode may be made without departing from the nature, spirit or scope of the invention, the invention is not to be limited to those details but only by a purposive reading of the appended claims as required by law. 

We claim:
 1. A grey water heat recovery apparatus comprising: at least a first heat exchanger pass having an external shell and a tube bundle; said external shell being formed of a cylindrical pipe; said cylindrical pipe having a first end and a second end; in operation, said first end being located higher than said second end; said second end being blocked to form a sump within said cylindrical pipe; said cylindrical pipe having a first port and a second port; said first port being nearer to said first end than to said second end; said first port being nearer said first end than is said second port; said first port defining a resting water level when gray water is contained in said sump; one of said first and second ports defining an inlet for grey water to said cylindrical pipe, the other of said first and second ports defining an outlet for grey water from said cylindrical pipe, said cylindrical pipe defining a flow path for grey water between said inlet and said outlet thereof; said first end of said cylindrical pipe providing an entry; said tube bundle being sized to fit within said entry at said first end of said pipe; said tube bundle being axially slidable within said external shell; said tube bundle having a first end and a second end; said tube bundle having a first manifold at said first end thereof, and a second manifold at said second end thereof; said tube bundle including an array of pipes, said pipes of said tube bundle being in fluid communication with said first manifold and said second manifold, said pipes of said array each having a respective first cross-sectional area; said tube bundle including a return extending upwardly beyond said first manifold and extending downwardly to said second manifold; said return having a second cross-sectional area; said first cross-sectional area being less than said second cross-sectional area, said first manifold and said second manifold fitting within said cylindrical pipe; as installed, said second end of said tube bundle being closer to said second end of said cylindrical pipe than is said first end of said tube bundle; said tube bundle having an inlet and an outlet, said tube bundle defining a fresh water flow path between said inlet and outlet thereof; both said inlet and said outlet of said tube bundle being located at said first end of said tube bundle; and as installed in said cylindrical pipe, said inlet and said outlet of said tube bundle being accessible at said first end of said cylindrical pipe at a level higher than said resting water level of said cylindrical pipe.
 2. The grey water heat recovery apparatus of claim 1 wherein said cylindrical pipe has at least one of (a) an inside diameter less than 8 inches; and (b) a length to diameter ratio of greater than 8:1.
 3. A grey water heat recovery apparatus comprising at least a first and a second heat recovery apparatus of claim 1 mounted side-by-side and joined together in fluid communication in series.
 4. The grey water heat recovery apparatus of claim 3 wherein at least said first and second heat recovery apparatus are mounted together within a single housing.
 5. The grey water heat recovery apparatus of claim 1 wherein said tube bundle includes a set of helical coils extending around said return.
 6. The grey water heat recovery apparatus of claim 1 wherein said second end of said cylindrical pipe has a valve mounted thereat, and said valve is operable to permit flushing of said sump.
 7. The grey water heat recovery apparatus of claim 1 wherein said apparatus includes a leak detector.
 8. The grey water heat recovery apparatus of claim 1 wherein said return is at least partially insulated.
 9. The grey water heat recovery apparatus of claim 1 wherein said array of pipes is spaced about said return pipe; and said array of pipes has a tighter footprint at said second manifold than at said first manifold.
 10. The grey water heat recovery apparatus of claim 1 wherein said second manifold has a smaller outside wall diameter than does said first manifold.
 11. A grey water heat recovery apparatus comprising: a pipe and a tube bundle; said pipe having a first end and a second end, said first end being an upper end and said second end being a lower end; said pipe having a cylindrical pipe wall and a first grey water port and a second grey water port formed in said cylindrical pipe wall; said first grey water port being closer to said first end of said pipe than to said second end of said pipe and defining a resting water level when grey water is contained within said pipe; said tube bundle having a first manifold, a second manifold, a return pipe, and a pipe array; said tube bundle including said first manifold and said second manifold insert axially to seat within said cylindrical pipe wall on installation; said pipe array of said tube bundle having at least a first pipe having a first cross sectional area; said return pipe having a second cross-sectional area; said second cross-sectional area being greater than said first cross-sectional area; said return pipe being in fluid communication with said second manifold and passing axially upwardly beyond said first manifold to terminate at a first pipe connection; said pipe array extending between, and being in fluid communication with both said first manifold and said second manifold; said first manifold having a second pipe connection extending upwardly therefrom, said second pipe connection being in fluid communication with said first manifold; and, at least one of (a) said pipe array has a smaller connection footprint with said second manifold than with said first manifold; and (b) said second manifold has a peripherally extending wall, said first manifold has a peripheral wall, and said peripheral wall of said second manifold has a shorter periphery than has said peripheral wall of said first manifold.
 12. The grey water heat recovery apparatus of claim 11 wherein said pipe array has a smaller connection footprint with said second manifold than with said first manifold.
 13. The grey water heat recovery apparatus of claim 11 wherein said second manifold has a peripherally extending wall, said first manifold has a peripheral wall, and said peripheral wall of said second manifold has a shorter periphery than has said peripheral wall of said first manifold.
 14. The grey water heat recovery apparatus of claim 11 wherein said first pipe has a straight portion extending axially from said first manifold, and a bent portion extending from said straight portion toward said second manifold.
 15. The grey water heat recovery apparatus of claim 14 wherein said straight portion is more than twice the length of said bent portion.
 16. The grey water heat recovery apparatus of claim 11 wherein: said peripheral wall of said first manifold has a first diameter; said peripheral wall of said second manifold has a second diameter; and said second diameter is smaller than said first diameter.
 17. The grey water heat recovery apparatus of claim 11 wherein said second manifold has a set of centering ears extending radially outwardly thereof.
 18. The grey water heat recovery apparatus of claim 17 wherein a grey water flow path is defined outwardly of said second manifold, inwardly of said cylindrical pipe, and sectorally between an adjacent pair of said centering ears.
 19. The grey water heat recovery apparatus of claim 11 wherein said pipe array has a total cross-sectional flow area that is at least as great as the cross-sectional flow area of said return pipe.
 20. The grey water heat recovery apparatus of claim 11 wherein: both of (a) said pipe array has a smaller connection footprint with said second manifold than with said first manifold; and (b) said second manifold has a peripherally extending wall, said first manifold has a peripheral wall, and said peripheral wall of said second manifold has a shorter periphery than has said peripheral wall of said first manifold; said first pipe has a straight portion extending axially from said first manifold, and a bent portion extending from said straight portion toward said second manifold; said straight portion is more than twice the length of said bent portion; said peripheral wall of said first manifold has a first diameter; said peripheral wall of said second manifold has a second diameter; said second diameter is smaller than said first diameter; said second manifold has a set of centering ears extending radially outwardly thereof; a grey water flow passage is defined outwardly of said second manifold, inwardly of said cylindrical pipe, and sectorally between an adjacent pair of said centering ears; and said pipe array has a total cross-sectional flow area that is at least as great as the cross-sectional flow area of said return pipe. 